Shaving razor package assembly

ABSTRACT

A shaving razor package assembly with a shaving razor package having a base with a perimeter wall defining a cavity. An upper surface of the perimeter wall has a flange and a recessed lip. The base defines a first opening. A handle having a first end is positioned within the first opening. An insert tray having a body is mounted to the base. The insert tray having a tab extending from the body. A bottom surface of the tab extends into the first opening and engages the first end of the handle. A lid is mounted over the insert tray and sealed to the base.

FIELD OF THE INVENTION

The present invention relates to packages for consumer products and moreparticularly, to product packages for shaving razors.

BACKGROUND OF THE INVENTION

Personal care articles such as shaving razors and tooth brushes aretypically sold in clear plastic product packages containing a pluralityof product units. These plastic packages are commonly referred to asblister packages and conventionally include a transparent plasticblister with a sheet or card material inside the package and/or as anouter seal which may add rigidity to the package and facilitatesuspension of the package from a hanger of a point-of-sale display. Thesheet and/or card material will usually be printed with appropriate dataconcerning the product within the pack. The pack is typically configuredso that on the point-of-sale display the blister is at the front so thatthe contents within the blister are clearly visible to the customer.Alternatively, the card may be located at the front with artworkillustrating the contents. The card and/or blister may be provided withtear perforations to provide access to the contents within the package.

Personal care articles items such as shaving razors, combs, brushes, andtooth brushes are typically suspended from retail pegs or placeddirectly on store shelves. Therefore, as used herein, the term“package”, or the phrase “product package” should be broadly construedto mean packaging for retaining personal care articles, such packagingbeing displayable.

Typically, individual product packages are received from a manufacturerin shipping containers with several individual product packagescontained loosely therein. These product packages must then be removedfrom the shipping container by a retail employee and mounted to thehanger of a point-of-sale display. The product is typically jostledduring shipment and mounting of the product to the point-of-saledisplay, which may affect the orientation of the product within thepackage. Some packages include a separate tray within the package whichholds a single product, however, these trays add extra cost and aretypically reused by the customer to hold or store the product after thepack is thrown away. Thus, these trays are not cost effective options.Disposable items that are packaged together (e.g., multiple disposablerazors or a handle and one or more cartridge packaged together) aretypically not secured and are allowed to move freely within the package.The movement of the items is limited only by the external shape of thepackage and the number of items in the package. Items that are notsecured to the package may change orientation by the time they reach thepoint-of-sale display.

In addition, conventional consumer goods packages frequently include asignificant amount of unused space or material and are not recyclable orare not easily recyclable. Consumers have become increasingly aware ofthe financial and environmental impact of such packaging and expectbusinesses that ship products to provide environmentally-friendly andcost-effective packaging.

Thus, there is a desire to overcome the problem associated with theholding and displaying multiple items within a consumer product package,such as a shaving razor package assembly.

SUMMARY OF THE INVENTION

In one aspect, the invention features, in general, a shaving razorpackage assembly with a shaving razor package having a base with aperimeter wall defining a cavity. The base defines a first opening. Ahandle having a first end is positioned within the first opening. Aninsert tray having a body is mounted to the base. The insert tray havinga tab extending from the body. A bottom surface of the tab extends intothe first opening and secures the first end of the handle. A lid ismounted over the insert tray and sealed to the base.

In another aspect, the invention features, in general, a method ofpackaging a shaving razor by providing a shaving razor package having abase. A first end of a handle is positioned within a first openingdefined by the base of the shaving razor package. An insert tray havingtab is mounted to the base. A first cartridge container is positionedwithin a first aperture defined by the insert tray. The first end of thehandle is temporarily secured within the first opening by positioning abottom surface of the tab within the first opening on top of the firstend of the handle.

In another aspect, the invention features, in general, a shaving razorpackage assembly with a shaving razor package having a base and aperimeter wall defining a cavity. An upper surface of the shaving razorpackage defines a recessed lip. A first protrusion spaced apart from asecond protrusion, each extending upward from the base to define a firstopening. A handle having a first end positioned within the firstopening. An insert tray mounted to the base. The insert tray having atab with a recessed top surface and an opposing bottom surface with aconcave region. A first cartridge container is positioned within a firstaperture that extends through the insert tray. The bottom surface of thetab extends into the first opening and engages the first end of thehandle. The razor package assembly may optionally include the inserttray having n raised or recessed brand indicia adjacent the firstaperture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one possible embodiment of a shavingrazor package assembly.

FIG. 2 is an assembly view of the shaving razor package assembly of FIG.1 .

FIG. 3 is perspective view of the shaving razor package assembly of FIG.1 with the lid removed for clarity.

FIG. 4 is a perspective view of an insert tray of FIG. 1 .

FIG. 5 is a perspective view of an alternative embodiment of an inserttray.

FIG. 6 is a cross section view, taken generally along the line 6-6 ofFIG. 1 .

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 , one possible embodiment of the present inventionis shown illustrating a shaving razor package assembly 10. The shavingrazor package assembly 10 may include a base 12 and a lid 14 sealed tothe base 12. The base 12 and/or the lid 14 may define an opening 16 todisplay the shaving razor package assembly 10 on a peg. The opening 16may be circular, a slot, or any other geometry known to those skilled inthe art for easy placement of the shaving razor package assembly 10 on apeg or hook. Hanging displays, such as peg boards offer increasedversatility for presenting articles to consumers. For example, pegboardracks that revolve or spin work extremely well for stores that havelimited floor space. A hanging display, such as a peg board, increasesthe versatility of packaging design because a flat surface is not neededto display the package on a shelf. This versatility allows for even morecreative package designs, thus allowing the article displayed on the pegboard to stand out even further from competitive products. However, itis understood that the shaving razor package assembly 10 may also bedisplayed on a shelf without the a hang hole 16.

The lid 14 may have a top face 18 that displays product graphics and/orinformation thereon, including but not limited to branding, producttitle, advertising, product instructions, advertising claims, productclaims, product comparisons, and/or any other graphics, information,text, etc., as desired. It is understood that the base 12 may alsocontain similar graphics and artwork. In certain embodiments, the lid 14may be substantially planar. While the base 12 shown in FIG. 1 issubstantially rectangular, it will be appreciated that a base may takethe form of any of a variety of suitable shapes, including, for example,the shape of the product contained within the package. In certainembodiments, a thickness of the base 12 may be from about 0.4 mm toabout 1.5 mm; from about 0.8 mm to about 1.25 mm; or in some examples,about 1.0 mm. The lid 14 and/or the base 12 may comprise one or morecellulose-based products such as cardboard, paperboard, paper sheet,bamboo and other sustainable, compostable, biodegradable orrecycled/recyclable materials. The lid 14 and/or the base 12 may also bemade from a slurry of water and pulp from fibrous materials, such asvirgin pulp or recycled paper products, or other natural fibers (e.g.,sugarcane, bamboo, wheat straw). The raw materials may help determinethe color, surface texture and strength of the lid 14 and/or base 12.The pulp may be formed into a shape by custom designed molds. The moldsare lowered into a pulp mixture and water is pulled through a mesh ofthe mold with a vacuum. An upper part of the mold may press into thelower part of the mold to arrive at the final shape. Although a varietyof sustainable materials are discussed, it is understood more durablematerials may also be used such as plastics. The lid 14 may be sealed tothe base 12 with a pressure sensitive adhesive or other conventionalmethods known to those skilled in the art.

Referring to FIG. 2 , an assembly view of the shaving razor packageassembly 10 is illustrated. The base 12 may have a perimeter wall 20that defines a cavity 22 for holding one or more products. The perimeterwall 20 may have an upper surface 24 with a recessed lip 26. One or moreprotrusions may extend from the base 12. For example a first protrusion28, a second protrusion 30, a third protrusion 32 and a fourthprotrusion 34 may extend from a bottom surface 36 of the base 12. Thecavity 22 may be dimensioned to receive a handle 38 having a first end40 and a second end 42. The base 12 may define a first opening 44 tohold a portion of the handle 38. For example, the first protrusion 28and the second protrusion 30 may be spaced apart to define the firstopening 44 dimensioned to receive the first end 40 of the handle 38. Thefirst protrusion 28 and the second protrusion 30 may be spaced apart toallow the first protrusion 28 and the second protrusion 30 to flex asthe handle 38 is inserted into the first opening 44, which may providefor improved securement of the handle 38. It is understood that althoughthe first protrusion 28 and the second protrusion 30 are spaced apart todefine the first opening 44, the first protrusion 28 and the secondprotrusion 30 may be partially interconnected for improved strength. Incertain embodiments, the first end 40 of the handle 38 may fit looselybetween the first and second protrusions 28 and 30 because of materiallimitations of the base 12.

The third protrusion 32 and the fourth protrusion 34 may be spaced apartto define a second opening 46 dimensioned to receive the second end 42of the handle 38. It is understood that although the third protrusion 32and the fourth protrusion 34 are spaced apart to define the secondopening 46, the third protrusion 32 and the fourth protrusion 34 may bepartially interconnected for improved strength. In certain embodiments,the second end 42 of the handle 38 may fit loosely between the thirdprotrusion 32 and the fourth protrusion 34 because of materiallimitations of the base 12. For example, pulp based materials (or othersustainable materials) may not have the same strength and rigidity ofpolymer based materials. Accordingly, press fitting the handle 38 withinthe first and second openings 44 and 46 may damage the base 12.

As shown in FIGS. 2 and 3 , an insert tray 48 may be provided to holdone or more cartridge containers 50 a and 50 b and/or shaving razorcartridges 55 a and 55 b. Each of the cartridge containers 50 a and 50 bmay hold the shaving razor cartridge 55 a and 55 b. The insert tray 48may include a body 52 that defines one or more apertures 54 and 56. Theapertures 54 and 56 may be dimensioned to receive the respectivecartridge containers 50 a and 50 b. It is understood that the apertures54 and 56 may extend completely through the insert tray 48 (as shown) oronly partially into the insert tray (e.g., recessed). In certainembodiments, the cartridge containers 50 a and 50 b may each have aflange 58 a and 58 b that rests on a top surface 60 of the body 52 ofthe insert tray 48. Although FIGS. 2 and 3 illustrate two apertures 54and 56 holding two cartridge containers 50 a and 50 b, it is understoodthat more apertures and cartridge containers may be used depending onthe desired package quantity. For example, club stores, larger countpackages may hold ten or more cartridges.

A tab 62 may extend from the body 52 of the insert tray 48. As will beexplained in greater detail below, the tab 62 may facilitate the removalof the insert tray 48 from the base 12 and facilitate the securement ofthe first end 40 of the handle 38 to the base 12. The tab 62 may definea recess 64. The recess 64 may be dimensioned to receive a thumb or afinger of a consumer to facilitate the removal of the insert tray 48from the base 12. Although, the cartridge containers 50 a and 50 b areillustrated as being positioned with the respective apertures 54 and 56,it is understood that the shaving razor cartridges 55 a and 55 b may bepositioned directly within the apertures 54 and 56 without the need ofusing an extra container. The cartridge containers 50 a and 50 b mayprovide a sealed compartment to control moisture and/or keep the shavingrazor cartridge(s) 55 a and 55 b clean. For example, the shaving razorcartridges 55 a and 55 b may have a lubrication member that may breakdown over time if exposed to a certain amount of moisture.

A bridge 70 may extend between the pair of apertures 54 and 56. Thebridge 70 may be positioned over the handle 38 and the cartridgecontainers 50 a and 50 b may be inserted into the respective apertures54 and 56 on either side of the bridge 70. The handle 38 may bepositioned between the pair of cartridge containers 50 a and 50 b.Lateral movement of the cartridge containers 50 b and 50 b may belimited by being positioned between the handle 38 and a respective sidewall 72 a and 72 b of the base 12. The insert tray 48 may rest on thebase 12. For example, a pair of lateral ends 66 and 68 of the body 52may be positioned on the recessed lip 26. Accordingly, the insert tray48 may be positioned at or below a flange 74 of the upper surface 24 ofthe base 12. The flange 74 may extend around a perimeter of the base 12with the lid 14 secured to the flange 74. The flange 74 may have aplurality of tabs 76, 78, 80 and 82. The body 52 of the insert tray 48may be positioned between the plurality of tabs 76, 78, 80 and 82 tominimize movement of the insert tray 48 and the cartridge containers 50a and 50 b. For example, the lateral end 66 of the body 52 may bepositioned between the tabs 80 and 82. Similarly, the lateral end 68 maybe positioned between tabs 76 and 78. As will be described in greaterdetail below, the tab 62 may be inserted into the opening 40 between thepair of protrusions 28 and 30 to secure the handle 38 within the cavity22 of the base 12.

Referring to FIG. 4 , a bottom perspective view of the insert tray 48 isillustrated. In certain embodiments, the pair of apertures 54 and 56 maybe positioned between a pair of flaps 84 and 86 that extend away from abottom surface 88 of the body 52 of the insert tray 48. The flaps 84 and86 may extend into the cavity 22 of the base 12 to facilitate alignmentand securement of the insert tray 48 to the base 12 (FIGS. 2 and 3 ).The tab 62 may have a bottom surface 90 to facilitate securement of thehandle 38. The tab 62 may also help secure the insert tray 48 to thebase 12. The bottom surface 90 may include a concave region 92 thatengages a corresponding area of the handle 38 (FIGS. 2 and 3 ). Incertain embodiments, the bottom surface 90 may be opposite the recess 64of the tab 62 (FIG. 3 ). For example, the recess 64 may be directlyopposite the concave region 92 of the tab 62. Accordingly, the tab 62facilitates easy removal of the insert tray 48 and facilitatessecurement of the handle 38 (FIG. 4 ).

Although the shaving razor package assembly 10 of FIG. 2 is showncontaining a shaving razor handle 38 and two cartridge containers 50 aand 50 b, it is understood that a similar package could be used for justone of the cartridge containers 50 a or 50 b. Referring to FIG. 5 , analternative embodiment (i.e., a single insert tray 94), of the inserttray 48 is illustrated. The single insert tray 94 may include a body 96defining an aperture 98. The aperture 98 may be dimensioned to receiveone of the cartridge containers 50 a or 50 b. The single insert tray 94may be very similar to the insert tray 48 illustrated in FIG. 4 , butthe insert tray 94 may include a brand indicia 100 instead of the secondaperture 56. The brand indicia 100 may include logos, letters, words,numbers and/or designs that are raised or recessed on the body 96 of theinsert tray 98. In certain embodiments, a bottom surface 99 of the body96 may define a break-away portion 101. Accordingly, the manufacturermay be able to easily punch out or remove the break-away portion 101 tocreate the insert tray 48 with the pair of apertures 54 and 56, as shownin FIG. 4 . In certain embodiments, the break-away portion 101 mayinclude half cuts, such that the break-away portion 101 does not extendto a top surface 103 of the body 96. Accordingly, the consumer may notnotice the break-away portion 101. The break-away portion 101 may makeit more efficient to produce an insert tray having different counts(e.g., a two count as shown for insert tray 48 of FIG. 4 or a singlecount, as shown for insert tray 98). However, it is understood that thebreak-away portion 101 may include perforations or slits that extend tothe top surface 103. In certain embodiments, the break-away portion 101may circumscribe the brand indicia 100.

A tab 102 may extend from the body 96. The tab may have a bottom surface104 with a concave region 106, similar to the insert tray 48 of FIG. 4 .The single insert tray 94 is illustrated without the flaps 84 and 86.However, it is understood that the flaps 84 and 86 are optional. Theinsert tray 48 and the single insert tray 94 may provide a simple way tooffer different cost figuration alternatives to the consumer.Accordingly, different configurations of the shaving razor packageassembly 10 (FIG. 1 ) may be easily implemented without causing consumerconfusion. For example, if the insert tray 48 is provided with only asingle cartridge container 50 a for a lower price point offering, theconsumer may see the aperture 56 in the insert tray 48 is empty andthink there is product missing. However, if the consumer sees the brandindicia 100 instead of the aperture 56 (which is empty), they will notbe confused as to how many cartridge containers 50 a and 50 b should beincluded in the shaving razor package assembly 10.

Referring to FIG. 6 , a cross section view of the shaving razor packageassembly 10, taken generally along the line 6-6 of FIG. 1 , isillustrated. The handle 38 may be positioned within the cavity 22 of thebase 12. The first end 40 of the handle 38 may be positioned within thefirst opening 44 defined by the first and second protrusions 28 and 30(FIG. 2 ). The first and second protrusions 28 and 30 may prevent thehandle 38 from shifting laterally within the base 12. The first end 40of the handle 38 may also be positioned between a lower surface 108 ofthe base 12 and the bottom surface 90 (e.g., concave region 92) of thetab 62 of the insert tray 48. Accordingly, the bottom surface 90 of thetab 62 may extend into the first opening 44 to facilitate securing thefirst end 40 of the handle 38. In certain embodiments, the bottomsurface 90 of the tab 62 may engage the handle 38. The first end 40 ofthe handle 38 may have a corresponding region (e.g., convex region 110)that engages the concave region 92 of the tab 62 for improved securementof the handle 38. The lid 14 may be mounted over the insert tray 48 andthe base 12. The lid 14 may be sealed to the base 12 (e.g., the flange74 of FIG. 3 ), but not the insert tray 48, which allows for easyremoval of the insert tray 48 from the base 12. The insert tray 48 maybe secured between the lid 14 and the base 12. In certain embodiments,the insert tray 48 may contact the lid 14 and the base 12 for improvedsecurity.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about mm” Furthermore, dimensions should not be held to an impossiblyhigh standard of metaphysical identity that does not allow fordiscrepancies due to typical manufacturing tolerances. Therefore, theterm “about” should be interpreted as being within typical manufacturingtolerances.

Every document cited herein, including any cross referenced or relatedpatent or application is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A shaving razor package assembly comprising: ashaving razor package having a base with a perimeter wall defining acavity, the base defining a first opening; a handle having a first endpositioned within the first opening; an insert tray having a bodymounted to the base, the insert tray having a tab extending from thebody, wherein a bottom surface of the tab extends into the first openingand secures the first end of the handle; and a lid mounted over theinsert tray and sealed to the base.
 2. The shaving razor packageassembly of claim 1 wherein the body of the insert tray defines a firstaperture.
 3. The shaving razor package assembly of claim 2 furthercomprising a cartridge container mounted within the first aperture. 4.The shaving razor package of claim 1 wherein the cartridge container hasa flange that sits on the top surface of the insert tray.
 5. The shavingrazor package of claim 2 wherein the insert tray defines a secondaperture.
 6. The shaving razor package of claim 2 wherein the body ofthe insert tray defines a break-away portion.
 7. The shaving razorpackage of claim 6 wherein the break-away portion comprises half-cuts.8. The shaving razor package of claim 1 wherein the handle is positionedbetween a first cartridge container extending into the first apertureand a second cartridge container extending into a second aperturedefined by the insert tray.
 9. The shaving razor package of claim 1wherein the tab defines a recess directly opposite a concave region ofthe bottom surface of the tab.
 10. The shaving razor package of claim 1wherein an upper surface of the perimeter wall has a flange and arecessed lip and the lid is sealed to the flange.
 11. The shaving razorpackage of claim 10 wherein the recessed lip supports a pair of lateralends of the insert tray.
 12. A method of packaging a shaving razorcomprising: providing a shaving razor package having a base; positioninga first end of a handle within a first opening defined by the base ofthe shaving razor package; mounting an insert tray having tab to thebase; temporarily securing the first end of the handle within the firstopening by positioning a bottom surface of the tab within the firstopening on top of the first end of the handle; mounting a lid over theinsert tray; and sealing the lid to the base.
 13. The method of claim 12further comprising positioning a first cartridge container within afirst aperture defined by the insert tray.
 14. The method of claim 13further comprising forming a break-away portion in the insert tray. 15.The method of claim 12 positioning a pair of lateral ends of a bottomsurface of the insert tray on top of a recessed lip of an upper surfaceof the shaving razor package.
 16. The method of claim 12 furthercomprising forming a raised or recessed brand indicia on the inserttray.
 17. The method of claim 13 wherein the positioning the firstcartridge container within the first aperture comprises positioning aflange of the first cartridge container on a top surface of the inserttray.
 18. The method of claim 12 further comprising positioning a secondend of the handle within a second opening defined by a second protrusionof the shaving razor package.
 19. A shaving razor package assemblycomprising: a shaving razor package having a base and a perimeter walldefining a cavity, an upper surface of the shaving razor packagedefining a recessed lip; a first protrusion spaced apart from a secondprotrusion, each extending upward from the base to define a firstopening; a handle having a first end positioned within the firstopening; an insert tray mounted to the base, the insert tray having atab with a recessed top surface and an opposing bottom surface having aconcave region; a first cartridge container positioned within a firstaperture extending through the insert tray, wherein the bottom surfaceof the tab extends into the first opening and engages the first end ofthe handle.
 20. The shaving razor package assembly of claim 19 whereinthe insert tray has raised or recessed brand indicia adjacent the firstaperture.